MT QM Pillar

QM
Micro Turners Pantnagar

QM Pillar Activity
Presentation By
S K Verma
Date : 19th March-2011
MICRO TURNERS PANTNAGAR
TPM - The Prime Mover Towards Excellence
CONTENTS
TOPICS
S. NO.
QM
SLIDE NO.
Background
Aim
Structure- QM Pillar
Targets
Scope
Activities on Customer Complaints - Warranty
08-19
Activities on Customer Complaints - EFR
20-28
Activities on Customer Complaints
29-50
Activities on In-process Rejection
51-69
10
Future Plan
70
BACKGROUND
QM
In-house Rejection
Warranty Rejection
WHY
QM ?
Inspection standard
not adequate
Customer Complaint
Reactive Approach
Aim- QM Pillar
QM
To establish defect free manufacturing process, where quality is

built into process, leading to consistent product performance and
quality into the hands of customer.
QM Pillar - STRUCTURE
QM
SK Verma
(PILLAR CHAIRMAN)
Mr. Praveen Kumar

( Machine Shop )
Mr. Sanjay
Verma
Mr.
Surender
Kumar
Mr. RN Singh
( Machine Shop )
Mr. VK
Singh
Mr. Gaurav
Tyagi
Mr. DD Giri
( HT & Plating )
Mr. Ajoy
Mukharji
Mr. Manoj
Bangali
QM-Targets
QM
QM SCOPE
QM
QM ACTIVITY
Customer complaint
prevention
activities
In process
defect
prevention
activities
Vendor component
defect prevention
activities
Warranty
M/c Shop
Bought out
Components
EFR
Heat
treatment
Job Work
Customer
Complaint
s
plating
In house
QM
Total warranty claims received till date from 6 to 24

months
of Vehicles sold month or 30,000 kms, whichever is
earlier.
WARRANTY
Warranty Claims Analysis
Flow
QM
Receipt of field parts /

Report from field
Analysis by CFT
members of all
interfacing function
Action identification
Manufacturing
related
Non
conformance
(NC to drawing
specification)
Design related
Basic
Design
Error
Robustness
to support
Mfg. &
Service
Field related
Periodic
maintenanc
e issues
Usage
issues
WARRANTY
Non Conformance
(NC to drawing
specification)
Analysis
Manufacturing related
Can detect
Make it detectable
Inspection Side
Inspectio
n Poka
Inspection
Plan
inadequate
Cause Side
Difference
in
standards
Inspection
Method wrong
Daily Check
List
MICRO
Feedback
Feedback
Update PQCP
Update PRBFM
Update Check sheets
TPM
Update
Inspection agreement
TURNERS
PANTNAGAR
Material
nonconformanc
e
Establish cause source

through QA matrix
Identify 4M & T
conditions
Kaizen for maintaining
4M & T conditions Sustenanc
Identify further possibilities & countermeasure
Feedback
Surface
coating
nonconformanc
e
Dimensional
nonconformance
Update Change/ Communize with reference

Inspection
to respective
Plan
Feedback
Cannot detect
Cause Side
Inspection
Plan
Poka
Yoke
QM
e
Machine
PM &
JH
Material
PPC &
QM
Method
KK, JH &
PM
- The Prime Mover Towards Excellence
Men
Tool
E&T &
QM
KK &
PM
10
WARRANTY
QM
11
WARRANTY
QM
DEFECT PHENOMENA MATRIX
12
WARRANTY
QM
13
WARRANTY
QM
DEFECT PHENOMENA MATRIX
14
WARRANTY
ANALYSIS
&ACTION
Part name
Model:
Phenomena
QM
: Shaft Kick
: All Model
: Crack / Broken
Probable Causes
Actions
Material Property 16MnCr5
Checked & found - OK
Surface Hardness 77/81

HRA
Checked & found OK ( 79/80

HRA )
Core Hardness 25/45 HRC
Checked & found OK ( 38 HRC )
Case depth 0.10/0.30 mm
Checked & found OK ( 0.30 mm )
5.
Plating Process Hydrogen

de-embrittle ment treatment
not done / not done
properly .
Ensure 100% Hydrogen deembrittle ment treatment in

Plating.
6.
Weak Design
Design has Changed by BAL

(Radius 3.5 to 4.2 mm & Dia 10
mm to 11.5 mm )
Sr.
no.
15
WARRANTY
QM
Action
Action: :Ensure
Ensure100
100%%Hydrogen
Hydrogende-embrittlement
de-embrittlementTreatment
Treatmentduring
duringPlating
Plating
16
WARRANTY
QM
IMPROVEMENT SHEET
Problem/Status:- Crack / Broken
Date of Implementation :- July- 2010
BEFORE
AFTER
Probable Cause:-
Counter Measure:-
-Weak Design.
1.
Radius 3.5 mm change to 4.2

mm
2.
Diameter 10 mm change to 11.5

mm
Idea:-
Change Design
17
WARRANTY RESULTS
Action
ActionTaken
Taken
July,10
July,10
QM
G
O
O
D
Old
OldPart
Part
Manufactured
Manufactured
ininmarch,10
march,10
18
WARRANTY
QM
Interaction with CQA BAL Akurdi for

Interaction with
CQA BAL Akurdi
for
understanding
& corrective
actions
understanding & corrective actions
19
QM
Warranty claims received in less then 6 months

of Vehicles sold or less then 3000kms, whichever is earlier.
20
EARLY FAILURE
AS per SAP data

AS per SAP data
As per Mfg. NC
As per Mfg. NC
QM
G
G
O
O
O
O
D
D
21
EARLY FAILURE DEFECT PHENOMENA

MATRIX
QM
22
EARLY FAILURE
QM
23
EFR (DEFECT PHENOMENA

MATRIX)
QM
24
ANALYSIS & ACTION - NOISY
QM
Noisy
Drive Assembly
Total Composite Tooth to Tooth

Error 0.10
Error 0.03
OK
OK
1.
2.
3.
Gear Starter Clutch
Tooth Profile
Error More
OK
OK
OK
OK
First Pc Inspection & Confirmed

In- Process 2/250 pcs Inspection.
Final Stage 100 % Inspection
1.
2.
Total Composite Tooth to Tooth

Error 0.10
Error 0.03
OK
OK
1.
2.
3.
Tooth Profile
Error More
OK
OK

Final Stage 100 % Inspection
KAIZEN

25
ACTIONS ON NOISY Gear Starter clutch
QM
26
EFR RESULTS
New
NewParts
Parts
Supply
Started
Supply Started
QM
GG
OO
OO
DD
Action
Action
Taken
Taken
27
WARRANTY
QM
Interaction with CQA BAL Akurdi for

Interaction with
CQA BAL Akurdi
for
understanding
& corrective
actions
understanding & corrective actions
28
QM
29
CUSTOMER COMPLAINT APPROACH
QM
30
CUSTOMER COMPLAINT
QM
1.1. BAL
BALQ
QBronze
BronzeAwardAward-Oct,
Oct,2008
2008
2.2. BAL
Q
Silver
AwardApr,2009
BAL Q Silver Award- Apr,2009
3.3. BAL
BALQ
QGold
GoldAwardAward-QualifiedQualified-Apr,2010
Apr,2010
New
NewParts
PartsSupply
Supplystarted
started
31
CUSTOMER COMPLAINT
QM
DEFECT PHENOMENA MONITORING
32
CUSTOMER COMPLAINT
QM
ANALYSIS & ACTIONS
33
CUSTOMER COMPLAINT
QM
ANALYSIS & ACTIONS
34
ACTION ON STEP AT DIA. IN DRIVE

ASSLY.
QM
35
CUSTOMER COMPLAINT
QM
IMPROVEMENT SHEET
Problem/Status:- Step on Dia. In Drive Assly
Date of Implementation :- 10.10.10
BEFORE
AFTER
Root Cause:-No mechanism for locking the Horizontal slide.
Counter Measure:- Plate & Bolt is attached with Machine to lock the
Horizontal Slide
Idea:- TO Make a provision to lock the Horizontal Slide
36
CUSTOMER COMPLAINT
QM
37
CUSTOMER COMPLAINT
QM
IMPROVEMENT SHEET
Problem/Status:- Total length Over size Bearing
Date of Implementation :- 18.11.2010
Race
BEFORE
AFTER
INSPECTION BY MICROMETER DURING SETTING
INSPECTION BY SNAP GAUGE DURING SETTING
Root Cause:-
Counter Measure:- Snap Gauge is provided on machine to avoid checking
- During setting Error in reading of Micrometer.
error.
Idea:- TO eliminate Inspection checking Error.
38
Zero Customer Complaint Sustenance
QM
Zero Customer Complaint Sustained By:1. Counter-measures on components arrested at Final inspection
stage.
2. PDI operator recognition
3. Q Methodology Implementation.
39
QM
1. Counter-measures on components arrested at PDI.

Daily defect monitoring sheet
40
QM
3. PDI operator recognition
41
Sustenance for Zero In-Process Defect
QM
42
QM
Component Study
43
QM
Critical dimension identification
44
QM
45
QM
46
QM
47
QM
48
QM
49
QM
50
QM
51
IN-HOUSE REJECTION
QM
52
IN-HOUSE REJECTION
QM
GOOD
53
IN-HOUSE REJECTION
QM
PROCESS WISE PPM & DEFECT PHENOMENA

2010-11
54
IN-HOUSE REJECTION
QM
DEFECT PHENOMENA MATRIX FOR FIRST TWO HIGH VALUE

REJECTION COST
55
IN-HOUSE REJECTION
QM
ANALYSIS & ACTIONS
56
IN-HOUSE REJECTION
QM
57
IN-HOUSE REJECTION
Kaizen
QM
58
IN-HOUSE REJECTION
-Kaizen (Plating)
QM
59
IN-HOUSE REJECTION
QM
60
IN-HOUSE REJECTION
QM
61
IN-HOUSE REJECTION
QM
ANALYSIS & ACTIONS - Sprocket
62
IN-HOUSE REJECTION
QM
63
IN-HOUSE REJECTION
QM
Defect
DefectPhenomena
Phenomena- -88nos.
nos.
HappenedHappened-22
Kaizen
Kaizen
- -22
PokaPoka- In-process
In-process
Yoke
Inspection
Yoke
Inspection
May
MayHappen
Happen- -66
Kaizen
Kaizen
PokaPokaYoke
Yoke
In-process
In-process
Inspection
Inspection- -66
64
IN-HOUSE REJECTION
QM
65
IN-HOUSE REJECTION
QM
66
IN-HOUSE REJECTION
QM
RESULTS SPROCKET CELL
All
AllActions
ActionsCompleted
Completed
Results
Results
GG
OO
OO
DD
67
IN-HOUSE REJECTION
QM
68
IN-HOUSE REJECTION
QM
69
FUTURE PLAN
QM
70
QM
THANK
YOU
71

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Micro Turners Pantnagar

TPM - The Prime Mover Towards Excellence

Activities on Customer Complaints - Warranty

Activities on Customer Complaints - EFR

Activities on Customer Complaints

Activities on In-process Rejection

MICRO TURNERS PANTNAGAR

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

To establish defect free manufacturing process, where quality is

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

Mr. Praveen Kumar

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

Total warranty claims received till date from 6 to 24

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

Receipt of field parts /

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

Establish cause source

Identify further possibilities & countermeasure

Update Change/ Communize with reference

- The Prime Mover Towards Excellence

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

DEFECT PHENOMENA MATRIX

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

DEFECT PHENOMENA MATRIX

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

Material Property 16MnCr5

Checked & found - OK

Surface Hardness 77/81

Checked & found OK ( 79/80

Core Hardness 25/45 HRC

Checked & found OK ( 38 HRC )

Case depth 0.10/0.30 mm

Checked & found OK ( 0.30 mm )

Plating Process Hydrogen

Ensure 100% Hydrogen deembrittle ment treatment in

Design has Changed by BAL

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

TPM - The Prime Mover Towards Excellence

Date of Implementation :- July- 2010

Radius 3.5 mm change to 4.2

Diameter 10 mm change to 11.5

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

Interaction with CQA BAL Akurdi for

MICRO TURNERS PANTNAGAR